Serial Number
Please use this number in registering your warranty
and any correspondence with the factory.
GENESIS®4000 Series
Natural Gas Barbecue
Owner’s Manual
FOR YOUR SAFETY
Do not store or use gasoline or other
flammable vapors and liquids in the
vicinity of this or any other appliance.
NOTICE TO INSTALLER: These
instructions must be left with the owner
and the owner should keep them for
future use.
WARNING: Follow all leak check
procedures carefully in this manual prior
to barbecue operation. Do this even if
barbecue was dealer assembled.
WARNING: Do not try to light this
appliance without reading "Lighting"
instructions section of this manual.
THIS GAS APPLIANCE IS DESIGNED FOR
OUTDOOR USE ONLY.
FOR YOUR SAFETY
If you smell gas:
1. Shut off gas to the appliance.
2. Extinguish any open flame.
3. Open lid.
4. If odor continues, immediately call
your gas supplier or your fire
department.
86016 6/96
®
2
DANGER
Failure to follow the Dangers, Warnings and Cautions contained in this Owner’s
Manual may result in serious bodily injury or death, or in a fire or an explosion causing
damage to property.
WARNINGS
■ Do not store a spare or disconnected LP tank under or near this barbecue.
■ Improper assembly may be dangerous. Please carefully follow the assembly instructions in this manual.
■ After a period of storage, and/or nonuse, the Weber Gas Barbecue should be checked for
gas leaks and burner obstructions before using. See instructions in this manual for correct
procedures.
■ Do not operate the Weber Gas Barbecue if there is a gas leak present.
■ Do not use a flame to check for gas leaks.
■ Combustible materials should never be within 24 inches of the top, bottom, back or sides of your
Weber Gas Barbecue.
■ Do not put a barbecue cover or anything flammable on or in the storage area under the barbecue.
■ Your Weber Gas Barbecue should never be used by children.
■ You should exercise reasonable care when operating your Weber Gas Barbecue. It will be hot during
cooking or cleaning, and should never be left unattended.
■ Should the burners go out during operation, turn all gas valves off. Open the lid and wait five minutes
before attempting to relight, using the lighting instructions.
■ Do not use charcoal or lava rock in your Weber Gas Barbecue.
■ Never lean over open grill or place hands or fingers on the front edge of the cooking box.
■ Should a grease fire occur, turn off all burners and leave lid closed until fire is out.
■ Do not enlarge valve orifices or burner ports when cleaning the valves or burners.
■ The Weber Gas Barbecue should be thoroughly cleaned on a regular basis.
■ LP gas is not natural gas. The conversion or attempted use of natural gas in an LP unit or LP gas in a
natural gas unit is dangerous and will void your warranty.
■ Do not attempt to disconnect any gas fitting while your barbecue is in operation.
■ Use heat-resistant barbecue mitts or gloves when operating barbecue.
LP GAS UNITS ONLY:
■ Use the regulator that is supplied with your Weber Gas Barbecue.
■ Do not attempt to disconnect the gas regulator or any gas fitting while your barbecue is in operation.
■ A dented or rusty LP tank may be hazardous and should be checked by your liquid propane supplier.
Do not use an LP tank with a damaged valve.
■ Although your LP tank may appear to be empty, gas may still be present, and the tank should be
transported and stored accordingly.
■ If you see, smell or hear the hiss of escaping gas from the LP tank:
1. Get away from LP tank.
2. Do not attempt to correct the problem yourself.
3. Call your fire department.
3
WARRANTYWARRANTY
Weber-Stephen Products Co. (Weber) hereby
warrants to the ORIGINAL PURCHASER of
this Weber Gas Barbecue that it will be free of
defects in material and workmanship from the
date of purchase as follows:
Aluminum Castings, 10 years,
Cooking Grates, 3 years,
Stainless Steel Flavorizer Bars, 5 years,
All Remaining Parts, 5 years,
when assembled and operated in accordance
with the printed instructions accompanying it.
Weber may require reasonable proof of your
date of purchase. THEREFORE, YOU
SHOULD RETAIN YOUR SALES SLIP OR
INVOICE.
This Limited Warranty shall be limited to the
repair or replacement of parts which prove
defective under normal use and service and
which on examination shall indicate, to
Weber's satisfaction, they are defective. Before
returning any parts, contact Weber-Stephen
Products Co. Customer Service Center. If
Weber confirms the defect and approves the
claim, Weber will elect to replace such parts
without charge. If you are required to return
defective parts, transportation charges must be
prepaid. Weber will return parts to the
purchaser, freight or postage prepaid.
This Limited Warranty does not cover any
failures or operating difficulties due to accident,
abuse, misuse, alteration, misapplication,
vandalism, improper installation or improper
maintenance or service, or failure to perform
normal and routine maintenance, including but
not limited to damage caused by insects within
the burner tubes, as set out in this owner's
manual.
Deterioration or damage due to severe
weather conditions such as hail, hurricanes,
earthquakes or tornadoes, discoloration due to
exposure to chemicals either directly or in the
atmosphere, is not covered by this Limited
Warranty.
There are no other express warrants except as
set forth herein and any applicable implied
warranties of merchantability and fitness are
limited in duration to the period of coverage of
this express written Limited Warranty. Some
states do not allow limitation on how long an
implied warranty lasts, so this limitation may
not apply to you.
Weber is not liable for any special, indirect or
consequential damages. Some states do not
allow the exclusion or limitation of incidental or
consequential damages, so this limitation or
exclusion may not apply to you.
Weber does not authorize any person or
company to assume for it any other obligation
or liability in connection with the sale,
installation, use, removal, return, or
replacement of its equipment; and no such
representations are binding on Weber.
This Warranty applies only to products sold at
retail.
WEBER-STEPHEN PRODUCTS CO.
Customer Service Center
250 South Hicks Road
Palatine, IL 60067-6241
(800) 446-1071
© 1996 Weber. Weber, , Genesis, Flavorizer and Crossover are
registered U.S. trademarks; Perma-Mount, Gas Catcher,
FlameCheck, Steam-N-Chips, Spider Stopper, and Warm-Up are
U.S. trademarks of Weber-Stephen Products Co., 200 East Daniels
Road, Palatine, IL 60067-6266. U.S.A. Genesis Gas Barbecues are
covered under the following patent nos.: U.S.A. #4,677,964;
4,727,853; #4,777,927; #4,829,978; #4,860,724; #4,941,817;
#4,966,125; #5,070,776; #D293,067; #D316,355; Canada: Rd
1987 Reg. #58,034; #1,279,540; #1,283,586; #1,300,994;
#1,300,995. Printed in the U.S.A.
4
PATENTS AND TRADEMARKS
5
Contents
WARNINGS................................................................ 2
Warranty & Patents.................................................. 3-4
General Instructions.................................................... 6
Assembly ............................................................... 7-24
Operating Instructions
Lighting ....................................................... 25-27
Cooking ............................................................ 28
Storage and/or Nonuse .................................... 28
Cleaning ........................................................... 28
Steam-N-Chips Smoker ................................... 29
Troubleshooting & Maintenance
Annual Maintenance ........................................ 30
General Maintenance.................................. 31-34
Troubleshooting .......................................... 35-36
Parts Listing .............................................................. 39
FEATURES:
a) Convenient tables and racks.
b) Heavy gauge porcelain-on-steel lid seals in heat.
c) Rapid read thermometer for precision cooking.
d) Stainless Steel Flavorizer Bars vaporize just the
right amount of drippings for flavoring.
e) Separate burners for temperature control.
f) Crossover Ignition System with Gas Catcher Ignition
Chamber.
g) Weber Warm-Up Basket for additional cooking or
warming space.
h) Locking casters for additional portability.
i) FlameCheck Safety System automatically shuts off
gas to the burners if the flame goes out.
j) Steam-N-Chips Smoker lets you add genuine smoke
flavor to any food prepared on this grill.
k) Side burner for making sauces, gravies, etc.,while
main grill is in use.
a
b
c
d
e
k
a
g
h
f
i
j
6
General Instructions
Your Weber Gas Barbecue is a portable outdoor
cooking appliance. With the Weber Gas Barbecue you
can grill, barbecue, roast and bake with results that are
difficult to duplicate with indoor kitchen appliances. The
closed lid and Flavorizer Bars produce that "outdoor"
flavor in the food.
The Weber Gas Barbecue is portable so you can easily
change its location in your yard or on your patio.
Portability means you can take your Weber Gas
Barbecue with you if you move.
The natural gas supply is easy to use and gives you
more cooking control than charcoal fuel.
■ These instructions will give you the minimum
requirements for assembling your Weber Gas
Barbecue. Please read the instructions carefully
before using your Weber Gas Barbecue. Improper
assembly can be dangerous.
■ Not for use by children.
■ If there are local codes that apply to portable gas
grills, you will have to conform to them. If there are
no local codes, you must conform to the latest
edition of the National Fuel Gas Code: ANSI Z
223.1.
■ This Weber Gas Barbecue is designed for natural
(piped in city) gas only. Do not use Liquid Propane
(LP) bottled gas.The valves, orifices and hose are
for natural gas only.
■ Do not use with charcoal fuel.
■ Check that the area under the control panel and the
bottom tray are free from debris that might obstruct
the flow of combustion or ventilation air.
■ The area around the LP tank must be free and clear
from debris.
For Installation in Canada
These instructions, while generally acceptable, do not
necessarily comply with the Canadian Installation
codes, particularly with piping above and below ground.
In Canada the installation of this appliance must comply
with local codes and/or Standard CAN/CGA-B149.1
(Installation Code for Natural Gas Burning Appliances
and Equipment).
Storage
■ The gas must be turned OFF at the natural gas
supply when the Weber Gas Barbecue is not in use.
■ When the Weber Gas Barbecue is stored
indoors, the gas supply must be disconnected.
Operating area
WARNING: Only use this barbecue outdoors in a
well ventilated area. Do not use in a garage,
building, breezeway or any other enclosed area.
■ Never use your Weber Gas Barbecue under an
unprotected combustible roof or overhang.
■ Your Weber Gas Barbecue is not intended to be
installed in or on recreational vehicles and/or boats.
■ Do not use combustible materials within 24 inches
of the top, bottom, back or sides of the grill.
■ The entire cooking box gets hot when in use. Do not
leave unattended.
■ Keep any electrical supply cord and the fuel supply
hose away from any heated surface.
■ Keep the cooking area clear of flammable vapors
and liquids, such as gasoline, alcohol, etc., and
combustible materials.
Gas supply testing
■ Disconnect your Weber Gas Barbecue when the
gas supply is being tested at high pressures. This
appliance and its individual shutoff valve must be
disconnected from the gas supply piping system
during any pressure testing of that system at test
pressures in excess of 1/2 psig (3.5 kPa).
■ Turn off your Weber Gas Barbecue when the gas
supply is being tested at low pressures. This
appliance must be isolated from the gas supply
piping system by closing its individual manual
shutoff valve during any pressure testing of the gas
supply piping system at the pressure equal to or
less than 1/2 psig (3.5 kPa).
Step 1
Check package contents
Cooking box
(assembly)
Lid
(assembly)
Hose
Bottom tray
Work table
Two accessory trays
Two swing tables
7
Assembly
Tools needed
Screwdrivers, regular
and Phillips
Hammer
7/16, 5/8, 11/16, and 3/4 inch open-end or two
adjustable wrenches
Pliers
Block of wood
Supplies needed
You will need a soap and water solution to check for gas
leaks. (See Step "Check for gas leaks.")
Note - The hardware size of nuts, bolts and screws is
given. For example "1/4-20 x 2 inch bolt" means a bolt
1/4 inch in diameter with 20 threads to the inch, 2 inches
long. On a small screw for example, "6-32 x 1/2 inch
screw" means a number 6 screw, with 32 threads to the
inch, 1/2 inch long.
®®®®®®®
®
While we give much attention to our products,
unfortunately an occasional error may occur.
If a part is missing, do not go back to the store.
Call the Weber Customer Service Center toll free
1-800-446-1071 to receive immediate assistance.
Have your owner’s manual and serial number of the
barbecue available for reference.
Serving tray
Control panel
Front panel
Left frame
Wheel frame
Two frame connectors
Five long Flavorizer Bars
Seven short Flavorizer Bars
Two wheels
Axle
8
Right frame
Caster frame
Cooking grate
Narrow cooking grate
Warming rack
Warm-Up Basket
Thermometer
Two aluminum drip pans
Catch pan
Catch pan holder
W
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B
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R
W
E
B
E
R
W
E
B
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R
W
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B
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R
9
Right hand slide bar assembly
Assembly consists of:
Right hand slide bar
Support
Slide
Left hand slide bar assembly
Assembly consists of:
Left hand slide bar
Support
Slide
Side burner assembly
Burner grate
Side burner knob
Two side burner locks
Steam-N-Chips Smoker body
Steam-N-Chips Smoker flue
Steam-N-Chips Smoker
water pan
10
Four 10-24 x 1 3/4 machine screws
(actual size)
Four 10-24 hex nuts
(actual size)
Nineteen 1/4 inch nylon washers
(actual size)
1/4-20 keps nut
Two hair pin cotters
Two swing table end brackets
Two casters
Check contents of hardware packs
Three burner control knobs
FlameCheck button
Three tool holders
Four tubing plugs
(two are spares)
Two wheel hubcaps
(actual size)
Two hinge pins
(hardware size: 1/4 x 1 1/2 inch clevis pin)
(actual size)
Five 1/4-20 x 2 inch bolts
(actual size)
Six 1/4-20 x 1/2 inch bolts
(actual size)
Manifold bracket
11
Step 2
Assemble wheels
You will need: axle, two wheel hubcaps, two wheels,
wheel frame, hammer and a block of wood.
Place one end of the axle on the block of wood (or other
protected surface). Tap on one hubcap.
Put one wheel on the axle, WEBER side toward the
hubcap. Slide the axle through the frame. Add the other
wheel, WEBER side out. Tap on the hubcap. Figure 1.
W
E
B
E
R
W
E
B
E
R
Figure 1
Step 3
Assemble frame
You will need: left frame, right frame, two nylon
washers, two 1/4-20 x 1/2 inch bolts and a 7/16 inch
wrench.
Note - Work on carpeted area (on grass, or on one of
the boxes) to protect the finish during frame assembly.
Put the frame pieces so the leg tabs are up. Put the right
frame to your right and left frame to your left. Figure 2.
Slip the two frame halves together with the tabs inside
,
until the tabs of the right frame are inside the left frame
and the holes align. Figure 2 (a).
Slip washers over bolts; insert and tighten bolts. (If you
try to insert a bolt and there are no holes, you have the
left frame turned the wrong way. Turn the left frame
around.) Figure 2 (b).
Left frame
Leg tabs
Frame tabs
Figure 2
(a)
(b)
Right frame
12
Step 4
Continue frame assembly
You will need: frame assembly, wheel frame assembly,
front panel, caster frame, four 1/4-20 x 1/2 inch bolts,
four nylon washers and a 7/16 inch wrench.
Place the caster frame onto the tabs of the left frame
with the dimple to the inside. Figure 3. Place the wheel
frame onto the tabs of the right frame with the dimple to
the inside. Figure 3.
The leg tabs must be on the inside of the frames.
Add front panel with the hole down and to your right.
Add the washers to the bolts, insert in the holes as
shown. Only start the bolts at the wheel frame,
figure 3 (a) & (b), and tighten the bolts at the
caster frame.
Dimples to
the inside
Only start
this bolt
Wheel frame
Caster frame
Figure 3
(a)
(b)
Step 5
Complete frame assembly
You will need: partial frame assembly, two frame
connectors, four 1/4-20 x 2 inch bolts, four nylon
washers and a 7/16 inch wrench.
Hold one frame connector between the caster and
wheel frame. Add nylon washers to the bolts. Put the
bolts through the frame and screw into frame connector.
Tighten.
Repeat procedure with the other frame connector.
Figure 4.
Figure 4
Step 6
Insert casters
You will need: frame assembly and two casters.
Push the casters firmly into the inserts in the ends of the
caster legs. Figure 5.
Figure 5
13
Step 7
Install side burner locks
You will need: frame assembly, 2 side burner locks and
a 7/16 inch wrench.
Turn frame assembly right side up.
Loosen the right rear 1/4 x 20 bolt. Install the side
burner lock. The “U” shape cut out of the lock slips down
over the bolt. Tighten with a wrench. Figure 6 (a).
Loosen the right front 1/4 x 20 bolt. The side burner lock
fits between the front panel and the frame.
The “U” shape cut out slips up over the bolt.
Tighten with a wrench.
Burner tubes
Figure 7
Frame brace
Step 8
Add cooking box
You will need: frame assembly, cooking box assembly,
1/4-20 x 2 inch bolt, nylon washer, 1/4-20 keps nut,
pliers and a 7/16 inch wrench.
Set the cooking box into the frame so the burner tubes
are under the frame brace. Figure 7.
Figure 6
(a)
(b)
Your Weber Gas Barbecue burner assembly has been
factory assembled, pressure and flame tested. As a
safety precaution we recommend you check the burner
alignment:
a) Do the valves fit into the ends of the burners?
Figure 9 (a).
b) Are the ends of the burners under the washers at
the left rear and left front of the cooking box? The
screws are only guides. Do not tighten. Figure 9 (b).
c) Are the wing nuts under the burner assembly
hand tight? Do not tighten with pliers. Figure 9 (c).
If you answered YES to a, b and c, the burners are
correctly aligned. If you answered NO, the burners are
misaligned. Contact Weber-Stephen Customer Service.
Do not use your barbecue.
Guide screw
Figure 9
(a)
(b)
(c)
Wing nuts
Slide the cooking box to the left within the frame. Put the
washer on the bolt. Insert the bolt through the cooking
box and frame with the head of the bolt outside the box.
Figure 8. Add keps nut. Tighten by holding the bolt with
pliers while you tighten the nut with the 7/16 inch wrench.
Figure 8
14
Step 9
Install gas supply
General Specifications for Piping
Note - Contact your local municipality for building
codes regulating outdoor gas barbecue
installations. In absence of Local Codes, you must
conform to the latest edition of ANSI Z223.1. WE
RECOMMEND THAT THIS INSTALLATION BE DONE
BY A PROFESSIONAL.
Some of the following are general requirements taken
from ANSI Z223.1, for gas supply installations. Refer to
ANSI Z223.1 latest edition for complete specifications.
■ This barbecue is designed to operate at 7 inches of
water column pressure (.2526 psi).
■ A manual shut-off valve must be installed outdoors,
immediately ahead of the quick disconnect.
CAUTION: If young children are in the area, a
locking valve should be considered.
■ An additional manual shut-off valve indoors should
be installed in the branch fuel line in an accessible
location near the supply line.
■ The quick disconnect connects to a 3/8 inch NPT
thread from the gas source. The quick disconnect
fitting is a hand-operated device that automatically
shuts OFF the flow of gas from the source when the
barbecue is disconnected.
■ The quick disconnect fitting can be installed
horizontally, or pointing downward. Installing the
fitting with the open end pointing upward can result
in collecting water and debris.
■ The dust covers (supplied plastic plugs) help keep
the open ends of the quick disconnect fitting clean
while disconnected.
■ Pipe compound should be used which is resistant to
the action of natural gas when connections are
made.
■ The outdoor connector must be firmly attached to
rigid, permanent construction.
WARNING: Do not route the 12’ hose under a
deck. The hose must be visible.
Typical natural gas supply installation. Figure 10.
Gas line piping
■ If the length of line required does not exceed 50
feet, use a 5/8" O.D. tube. One size larger should be
used for lengths greater than 50 feet.
■ Gas piping may be copper tubing, type K or L;
polyethylene plastic tube, with a minimum wall
thickness of .062 inch; or standard weight (schedule
40) steel or wrought iron pipe.
■ Copper tubing must be tin-lined if the gas contains
more than 0.3 grams of hydrogen sulfide per 100
cubic feet of gas.
■ Plastic tubing is suitable only for outdoor,
underground use.
■ Gas piping in contact with earth, or any other
material which may corrode the piping, must be
protected against corrosion in an approved manner.
■ Underground piping must have a minimum of
18" cover.
Test connections
All connections and joints must be thoroughly tested for
leaks in accordance with local codes and all listed
procedures in the latest edition of ANSI Z223.1.
Figure 10
The quick disconnect
is installed above ground
Gas supply
Outside wall
Inside wall
Quick disconnect
Male fitting
To barbecue
Shut off
Locking
Shut off
DANGER
Do not use an open flame to check for gas
leaks. Be sure there are no sparks or open
flames in the area while you check for gas
leaks. This will result in a fire or explosion
which can cause serious bodily injury or
death, and damage to property.
15
Step 10
Install igniter
Note - The igniter wires are already attached to the Gas
Catcher Ignition Chamber and the igniter. This was done
to factory test the ignition system.
The igniter lock nut is on the igniter.
Insert the top of the igniter up through the large part of
the keyhole in the frame brace. Loosen the igniter lock nut
and slide the igniter into the small part of the keyhole.
Tighten the igniter lock nut. Figure 11.
Note - If the igniter works loose, carefully tighten the
igniter lock nut with an adjustable wrench or pliers.
Figure 11
Igniter lock nut
Keyhole in
frame brace
Step 11
Check that all burner valves are off
You will need: one burner control knob.
(Valves are shipped in the OFF position, but you should
check to be sure.) Put the knob on each valve. Check by
pushing down and turning clockwise. If they do not turn
they are off, proceed to the next step. Figure 12.
Figure 12
Step 12
Connect flexible hose to manifold
You will need: the 12 foot natural gas supply hose and a
3/4 inch wrench.
Thread fitting end of hose onto manifold. Figure 13.
Tighten with wrench.
Figure 13
Small part of
keyhole in
frame brace
Frame brace
Frame brace
(a)
(b)
(c)
16
Step 13
Install side burner
You will need: side burner assembly, burner grate,
3/4 inch, 5/8 inch and an 11/16 inch or two adjustable
wrenches.
CAUTION: No sealant is required on the side
burner fitting. Do not use pipe dope, tape or any
other type of sealant on the fittings or hose.
Use an 11/16 wrench to remove the protective brass cap
from the side burner fitting on the manifold. Figure 14.
CAUTION: When removing the cap use a 5/8 inch
wrench to "hold" the side burner fitting to keep it
from becoming loose. If the side burner fitting
should loosen, tighten before attaching side burner
hose.
Slide the side burner assembly into the open end of the
right frame. Route the side burner hose so that it
parallels the front of the barbecue. Loop the hose so
that it reaches the side burner fitting. Attach hose and
tighten with a 3/4 inch wrench. Figure 15. Install burner
grate. Check to be sure the side burner valve is OFF.
Push side burner control knob down and turn clockwise.
Figure 14
Figure 15
Step 14
Install manifold bracket
You will need: manifold bracket
Hook the bracket onto the manifold at the center burner
valve. Figure 16. Place your hand underneath the
bracket. Lift the bracket, manifold and cooking box
slightly as a unit and hook onto the frame brace.
Figure 16
Frame brace
Cap
Side burner fitting
Manifold bracket
17
Slot in frame
(view from below)
Insert one end of the hinge rod into the hole in the
frame. Figure 18 (a).
Insert the other end into the hole in the swing table end
bracket. Figure 18 (b). Hold the end bracket at an angle so
the lower tab is inside the frame tube. Push the bracket into
the frame. Check to see that the lower tab of the bracket is
hooked in the slot in the frame. Figure 18 (c).
To fully seat the bracket, you may have to tap it lightly with a
hammer.
WARNING: If swing table end bracket is in any
way cracked or damaged, do not use swing table.
Call our Customer Service Center to order a new
part.
WARNING: The load limit for the swing table is
30 pounds.
Figure 18
(c)
View from rear
of barbecue
Hinge rod
(b)
(a)
Step 15
Install left hand swing table
You will need: swing table end bracket, two 10-24 hex
nuts, two 10-24 x 1 3/4 inch machine screws, left hand
slide bar assembly, swing table, four nylon washers,
screwdriver and pliers.
Allow the slide bar to hang down. Push the support rod
into the lower support bracket. Figure 17 (a). Swing the
rod up so you can slide the rod all the way inside the
locking tab. Figure 17 (b). The rod should swing freely
inside the locking tab. Figure 17 (c).
Figure 17
(a)
(b)
(c)
Support rod
18
Position slide bar assembly on the outside of the caster
frame. Put a nylon washer on each 1 3/4 inch screw,
insert screws through frame and slide bar assembly and
add nylon washers and hex nuts. Tighten nuts using a
screwdriver and pliers. Figure 19.
Figure 19
View from front
of barbecue
Notch to the front
Slide bar
To lower table: Pull support rod up to disengage slide
lock, and lower table. To raise table, lift table up and
engage slide in locked position. Figure 20.
View from rear
of barbecue
Support rod
Locked position
Unlocked position
Figure 20
Slide
Step 16
Install right hand swing table
You will need: swing table end bracket, two 10-24 hex
nuts, two 10-24 x 1 3/4 inch machine screws, right
hand slide bar assembly, swing table, four nylon
washers, screwdriver and pliers.
Allow the slide bar to hang down. Push the support rod
into the lower support bracket. Figure 21 (a). Swing the
rod up so you can slide the rod all the way inside the
locking tab. Figure 21 (b). The rod should swing freely
inside the locking tab. Figure 21 (c).
Figure 21
(a)
(b) (c)
View from rear
Support rod
Slide bar
assembly
19
Figure 22
View from rear
of barbecue
Hinge rod
Figure 23
Figure 24
To lower table: Pull support rod up to disengage slide
lock and lower table. To raise table, lift table up and
engage slide in locked position. Figure 24.
Notch
Slide bar
Unlocked position
Slide
Support rod
Locked position
Wheel frame
View from front
of barbecue
Slot in frame
(view from below)
Insert one end of the hinge rod into the hole in the
frame. Figure 22 (a).
Insert the other end into the hole in the swing table end
bracket. Figure 22 (b). Hold the end bracket at an angle so
the lower tab is inside the frame tube. Push the bracket into
the frame. Check to see that the lower tab of the bracket is
hooked in the slot in the frame. Figure 22 (c).
To fully seat the bracket, you may have to tap it lightly with a
hammer.
WARNING: If swing table end bracket is in any
way cracked or damaged, do not use swing table.
Call our Customer Service Center to order a new
part.
WARNING: The load limit for the swing table is
30 pounds.
(b)
(c)
(a)
Position slide bar assembly on the outside of the wheel
frame. Put a nylon washer on each 1 3/4 inch screw,
insert screws through wheel frame and slide bar
assembly and add nylon washers and hex nuts. Tighten
nuts using a screwdriver and pliers. Figure 23.
20
Step 17
Check for gas leaks
WARNING: You should check for gas leaks every
time you disconnect and reconnect a gas fitting.
Note - All factory made connections have been
thoroughly checked for gas leaks. The burners have
been flame tested. As a safety precaution you should
recheck all fittings for leaks before using your Weber
Genesis Gas Barbecue. Shipping and handling may
have loosened or damaged a gas fitting.
WARNING: Perform these leak checks even if
your barbecue was dealer or store assembled.
You will need: FlameCheck button, a soap and water
solution and a rag or brush to apply it.
Note - Since some leaks test solutions, including soap
and water, may be slightly corrosive, all connections
should be rinsed with water after checking for leaks.
Make sure side burner is OFF. Remove valve control
knob and screws. Remove porcelain top. Figure 25.
To perform leak checks: Slide back the collar of the
quick disconnect. Push male fitting of the hose into the
quick disconnect, and maintain pressure. Figure 26 (a).
Slide the collar closed. Figure 26 (b). If it does not
engage or lock, repeat procedure. Gas will not flow
unless the quick disconnect is properly engaged.
Turn on gas supply.
DANGER
Do not use an open flame to check for
gas leaks. Be sure there are no sparks or
open flames in the area while you check for
leaks. This will result in a fire or explosion
which can cause serious bodily injury or
death and damage to property.
Figure 25
Figure 26
Put the FlameCheck button on the FlameCheck valve.
When checking for gas leaks, push the FlameCheck
button down and hold down until leak checking is
complete. This will allow gas to fill the hoses and
manifold. Figure 27.
WARNING: Do
not ignite burners while leak
checking.
Check for leaks by wetting the connections with the
soap and water solution and watching for bubbles. If
bubbles form or if a bubble grows there is a leak.
To barbecue
Locking shut off
Outside
house wall
Male fitting
Quick disconnect
engaged
Collar
(a)
(b)
Figure 27
21
Check:
a) Hose to manifold connection. Figure 28 (a).
b) Manifold to side burner hose connection.
Figure 28 (b).
WARNING: If there is a leak at connection (a),
retighten the fitting with a wrench and recheck for
leaks with soap and water solution.
If a leak persists after retightening the fitting, turn
OFF the gas. DO NO
T OPERATE THE BARBECUE.
Contact Weber-Stephen Customer Service.
c) Side burner hose to side burner connection.
Figure 28 (c).
d) Valves to manifold connections. Figure 28 (d).
e) Hose to quick disconnect connection. Figure 28 (e).
WARNING: If there is a leak at connections (b), (c),
(d) or (e), turn OFF the gas. DO NO
T OPERATE THE
BARBECUE. Contact Weber-Stephen Customer
Service.
When leak checks are complete, turn gas supply OFF at
the source and rinse connections with water.
Figure 28
(a) (b)
(c)
(d)
(e)
Place the short Flavorizer Bars in place in the upper
positions in the cooking box. Set the Steam-N-Chips
Smoker body on the flue and across the long Flavorizer
bars. Figure 30.
Step 18
Insert Flavorizer Bars and Steam-N-Chips Smoker
You will need: five long Flavorizer Bars, seven short
Flavorizer Bars, Steam-N-Chips Smoker body and flue.
Place the three long Flavorizer bars in the rear of the
cooking box. Insert the remaining two bars through the
Steam-N-Chips Smoker flue and set into place in the
cooking box. Figure 29.
Figure 29
Figure 30
22
Step 20
Install the bottom tray
You will need: bottom tray, catch pan holder, catch pan
and one drip pan.
Hook the ends of the catch pan holder into the hole in the
bottom tray. Figure 33. The front of the catch pan
holder must be on the same side as the finger grip of
the bottom tray.
Slide the bottom tray onto the mounting rails under the
cooking box with finger grip toward you. Figure 34.
CAUTION: Do not line bottom tray with aluminum
foil. It can cause grease fires by trapping the grease
and not allowing grease to flow into the catch pan.
Put the foil drip pan into the catch pan.
Slide the catch pan into the catch pan holder with its
finger grip towards you.
Figure 33
Figure 32
Figure 34
Bottom tray
Finger grip on front
edge of bottom tray
Finger grip
Front side of catch
pan holder
Step 19
Install cooking grates
You will need: two cooking grates.
The open "U" of the cooking grates goes down. The
wide cooking grate goes to the right, narrow grate goes
to the left side of the cooking box. Set the cooking
grates onto the ledges in the cooking box. Figure 31.
Figure 31
23
Step 21
Install the lid
You will need: lid, two hinge pins and two hair pin cotters.
Set the lid in place. Align the hinges at the rear of the
barbecue. Insert hinge pins from the outside. Insert hair
pin cotters into the small holes in the hinge pins.
Figure 35.
Figure 35
Hair pin cotter
Hinge pin
Step 22
Install tool holders, control panel, burner control knobs and FlameCheck button
You will need: three tool holders, control panel, three
burner control knobs and FlameCheck button.
Hook the tool holders over the frame rail. Figure 36.
Set the control panel in place over both frame braces.
(Hold the Crossover Ignition button up while setting the
control panel in place.) Place your thumbs over the
control panel push-in buttons and push them into the
frame brace until they snap into place. Figure 36 (a).
Push on the burner control knobs and FlameCheck
button. Figure 36 (b).
Figure 36
Hole in frame brace
Tool holders
(a)
(b)
Control panel
push-in buttons
24
Step 24
Complete accessory installation
You will need: work table, two accessory trays, serving
tray, Warm-Up Basket, warming rack, thermometer, two
tubing plugs and a hammer.
Insert one end of the Weber Warm-Up Basket into the
hole in the right end of the lid and the other end into the
slot in the left end of the lid. Figure 38 (a).
Set the work table onto the left side rails. Figure 38 (b).
Place porcelain serving tray on the work table.
Figure 38 (c).
Set the accessory trays between the two frame
connectors. Figure 38 (d).
Set the warming rack into the slots at the rear of the
cooking box. Figure 38 (e).
Insert the thermometer into its holder. Figure 38 (f).
Insert tubing plugs into the ends of the frame. To fully seat
the plugs, you may have to tap them lightly with a
hammer. Figure 38 (g).
Figure 38
(a)
(e)
(f)
(g)
(b)
(d)
(c)
Step 23
Secure side burner
Pull the right hand swing table up. Stand to the right side
of the barbecue. Slightly pull back both side burner
locks. Slide the side burner toward the control panel.
The locks will snap into the slots in the front and back of
the side burner. Figure 37.
Figure 37
View from top
Side view
CAUTION: To keep the barbecue stationary, the
tabs on the locking casters should be in the down
position.
2525
Lighting
Summary lighting instructions are on the control panel.
Crossover Ignition System
Note - The Crossover Ignition System ignites the Front
burner with a spark from the igniter electrode inside the
Gas Catcher Ignition Chamber. You generate the energy
for the spark by pushing the Crossover Ignition Button
until it clicks.
WARNING: Check hose before each use of
barbecue for nicks, cracking, abrasions or cuts. If
the hose is found to be damaged in any way, do not
use the barbecue. Replace using only Weber
authorized replacement hose. Order from WeberStephen Products Co., Customer Service Center or
authorized dealer.
Figure 1
Crossover Ignition System
3) Turn gas supply valve on.
4) Push Front burner control knob down and turn to
START/ HI.
WARNING: Do not lean over open barbecue. Keep
your face and body at least one foot away from the
matchlight hole when lighting the barbecue.
5) Push down the FlameCheck button and hold down.
Note - Gas is supplied to the burner only when the
FlameCheck button is depressed.
6) Push the Crossover Ignition button several times, so
that it clicks each time.
7) Check that the burner is lit by looking through the
matchlight hole on the front of the cooking box.
If the burner is lit, continue to hold the FlameCheck
button down for about 8 seconds. When the button is
released the burner will stay lit.
WARNING: If the burner does not light, turn the
Front burner control knob to OFF and wait 5
minutes to let the gas clear before you try again or
try to light with a match.
8) After the FRONT burner is lit you can turn on the
other burners.
Note - The FRONT burner must be on at all times when
operating the other burners. The FlameCheck Safety
System monitors the Front burner. For your safety, the
FlameCheck valve will shut off the gas to the burners if
the front burner should inadvertently go out during
cooking.
To Extinguish
Turn gas supply OFF at the source, then push down
and turn each burner control knob clockwise to
OFF.
OPERATING INSTRUCTIONS
DANGER
Failure to open lid while igniting the
barbecue, or not waiting 5 minutes to
allow the gas to clear if the barbecue does
not light, may result in an explosive flameup which can cause serious bodily injury
or death.
1) Open the lid. Figure 1.
2) Make sure all burner control knobs are turned OFF.
(Push each burner control knob down and turn
clockwise.)
1
2
8
3
7
4
5
6
26
5) Strike a match and put the flame into the matchlight
hole in the front of the cooking box.
6) Push down and hold the FlameCheck button down.
Note - Gas is supplied to the burner only when the
FlameCheck button is depressed.
7) Check that the burner is lit by looking through the
matchlight hole on the front of the cooking box.
If the burner is lit, continue to hold the FlameCheck
button down for about 8 seconds. When the button
is released the burner will stay lit.
WARNING: If the burner does not light, turn the
Front burner control knob to OFF and wait 5 minutes
to let the gas clear before you try again or try to light
with a match.
8) After the FRONT burner is lit you can turn on the
other burners.
Note - The Front burner must be on at all times when
operating the Center or Back burners. The FlameCheck
Safety System monitors the Front burner. For your
safety, the FlameCheck valve will shut off the gas to the
burners if the front burner should inadvertently go out
during cooking.
To Extinguish
Turn gas supply OFF at the source, then push down
and turn each burner control knob clockwise to OFF.
Manual Lighting
1) Open the lid. Figure 2.
2) Make sure all burner control knobs are turned OFF.
(Push each knob down and turn clockwise.)
3) Turn gas supply valve on.
4) Push Front burner control knob down and turn to
START/ HI.
WARNING: Do not lean over open barbecue. Keep
your face and body at least one foot away from the
matchlight hole when lighting the barbecue.
5
7
1
2
3
4
6
8
Figure 2
Manual Lighting
DANGER
Failure to open lid while igniting the
barbecue, or not waiting 5 minutes to
allow the gas to clear if the barbecue does
not light, may result in an explosive flameup which can cause serious bodily injury
or death.
27
Lighting the side burner
The side burner has a separate ignition system from the
main cooking box.
The side burner will only operate when the Front
burner is lit.
1) Open the side burner lid. Figure 3.
2) Push down and turn the side burner control to HI.
3) Push the side burner igniter button several times so
it clicks each time.
CAUTION: Side burner flame may be difficult to
see on a bright sunny day.
WARNING: If the side burner does not light:
a) Turn OFF the side burner control valve.
b) Wait 5 minutes to let the gas clear before you try
again or try to light with a match.
3
2
1
Figure 3
DANGER
Failure to open lid while igniting the
side burner, or not waiting 5 minutes to
allow gas to clear if the side burner does
not light, may result in an explosive flameup which can cause serious bodily injury
or death.
28
Cooking
The Weber Gas Barbecue should not be moved
when operating or hot.
You can adjust the FRONT, CENTER and BACK burners
as desired. The control settings High (H), Medium (M),
Low (L), or Off (O) are described in your Weber
cookbook. The cookbook uses these notations to
describe the settings of the FRONT, CENTER, and
BACK burners. For example, to sear steaks you would
use (HHH) (all burners at high). Then to complete
cooking you would use (MOM) (FRONT at medium,
CENTER off, and BACK at medium). See your Weber
cookbook for detailed cooking instructions.
If burners go out during cooking, open lid, turn off
all burners and wait 5 minutes before relighting.
Note: The temperatures inside your cooking box, for the
first few uses, while surfaces are still very reflective,
may be hotter than those shown in your cookbook.
Cooking conditions may require the adjustment of the
burner controls to attain the correct cooking
temperatures.
CAUTION: Replace thermometer in lid when not in
use. Do not leave thermometer in food while cooking.
Preheating
Your Weber Gas Barbecue is an energy efficient
appliance. It operates at a low B.T.U. rate for economy.
To preheat, after lighting, close lid and turn all burners to
high (HHH). Preheating to between 500° and 550° F
(260° and 290° C) will take 10 to 15 minutes depending
on conditions such as air temperature and wind.
Drippings and grease
The Flavorizer Bars are designed to "smoke" the right
amount of drippings for flavorful cooking. Excess
drippings and grease accumulate in the catch pan under
the bottom tray. Disposable foil liners are available that
fit the catch pan.
CAUTION: Check the bottom tray for grease buildup before each use. Remove excess grease to avoid
a grease fire in the bottom tray.
Periodic Cleaning
CAUTION: Turn your Weber Gas Barbecue OFF
and wait for it to cool before cleaning.
CAUTION: Do not clean your Flavorizer Bars or
cooking grates in a self-cleaning oven. Replacement
cooking grates and Flavorizer Bars are available
through your retailer or the Weber-Stephen Customer
Service Center.
Outside surfaces - Use a warm soapy water solution.
CAUTION: Do not use oven cleaner, abrasive
cleansers (kitchen cleansers), cleaners that contain
citrus products or abrasive cleaning pads on
barbecue or cart surfaces.
Bottom tray - Remove excess grease and then wash
with warm soapy water.
Flavorizer Bars and Cooking Grates - Clean with a
suitable brass bristle brush. As needed, remove from grill
and wash with soapy warm water.
Catch pan - Disposable foil trays are available, or you can
line the catch pan with aluminum foil. To clean the catch
pan, wash with warm soapy water.
Thermometer - Wipe with warm soapy water, clean with
plastic scrub ball. Do not put in dishwasher or submerge
in water.
Inside cooking box - Brush any debris off of burners
tubes. DO NOT ENLARGE BURNER PORTS
(OPENINGS). Wash inside of cooking box with warm
soapy water.
Inside Lid - While lid is warm, wipe inside with paper
towel to prevent flaking due to grease build-up.
Storage and/or Nonuse
■ When storing the Weber Gas Barbecue, make sure
that the inside shut off valve and/or locking outdoor
shut off valve is secured in the OFF position. When
the Weber Gas Barbecue is stored indoors, the gas
supply MUST BE DISCONNECTED.
■ After a period of storage and/or nonuse the Weber
Gas Grill should be checked for gas leaks and any
obstructions in the burner tubes before using. (See
Sections General and Annual Maintenance.)
■ Check that the areas under the control panel and
the bottom tray are free from debris that might
obstruct the flow of combustion or ventilation air.
■ The Spider Stopper Guards should also be checked
for any obstructions. (See Section "Annual
Maintenance.")
29
Using the Steam-N-Chips Smoker
The Steam-N-Chips Smoker cooks with both Weber
FireSpice Wood Chips and Chunks. For best results with
faster cooking foods like steaks, burgers and chops, etc.,
we recommend using the FireSpice Chips because they
ignite and create smoke faster. For longer cooking foods
such as roasts, chicken and turkeys, etc., we recommend
using FireSpice Chunks because they ignite slowly and
provide smoke for a longer period of time. As you gain
experience in using your Steam-N-Chips Smoker, we
encourage you to experiment with different combinations
of FireSpice Chips and Chunks to find the smoke flavor
that best suits your taste.
To use the Steam-N-Chips Smoker
As a starting point, place a handful of FireSpice Chips or
a few FireSpice Chunks in the bottom of the smoker body.
Figure 4. Since the chunks vary in size, place as many as
you can in the smoker allowing room for the water pan.
As you gain experience in smoking, increase or decrease
the amount of wood to suit your taste. Fill water pan,
place it in the smoker and close the smoker lid.
Light the barbecue and preheat with all burners on HIGH,
lid down, for 10 minutes or until thermometer registers
500°F - 550°F. Adjust the burners for cooking; MOM or
LOL will be your best settings for long duration smoking.
Smoke will start in approximately 10 minutes and last as
long as 45 minutes. If you require more smoke flavor, refill
the smoker with FireSpice Chips and/or Chunks and refill
the water pan with water. The Steam-N-Chips Smoker
may be used to enhance any of the meat, poultry and fish
recipes in the gas barbecue cookbook. Cook with the lid
down according to the times indicated in charts
or recipes.
Note - After refilling smoker, smoke will take about 10 to
15 minutes to start again.
Cutaway view
Cleaning the Steam-N-Chips Smoker
Before each use, empty the Steam-N-Chips Smoker of
ash to allow proper air flow. Accomplish this by lightly
tapping the sides of the smoker and stirring the ashes so
that they sift through the bottom and fall into the bottom
tray of your barbecue. Remove bottom tray and empty.
Note - Smoking will leave a "smoke" residue on the
surface of the smoker. This residue cannot be removed
and will not affect the function of the Steam-N-Chips
Smoker. To a lesser degree a "smoke" residue will
accumulate on the inside of your Weber Gas Barbecue.
This residue need not be removed and will not adversely
affect the function of your Weber Gas Barbecue.
DANGER
Do not use any flammable fluid in the
Steam-N-Chips Smoker to ignite the wood.
This will cause serious bodily injury.
Place wood in here
Steam-N-Chips Flue
Figure 4
Water Pan
Steam-N-Chips Body
30
WARNING: If there is a leak at connection (a),
retighten the fitting with a wrench and recheck for
leaks with soap and water solution.
If a leak persists after retightening the fitting, turn
OFF the gas. DO NO
T OPERATE THE BARBECUE.
Contact Weber-Stephen Customer Service.
c) Side burner hose to side burner connection.
Figure 5 (c).
d) Valves to manifold connections. Figure 5 (d).
e) Hose to quick disconnect connection. Figure 5 (e).
WARNING: If there is a leak at connections (b),
(c), (d) or (e), turn OFF the gas. DO NO
T OPERA
TE
THE BARBECUE. Contact Weber-Stephen Customer
Service.
When leak checks are complete, turn gas supply OFF at
the source and rinse connections with water.
Annual Maintenance
After a period of nonuse we recommend that you
perform the following maintenance procedures f
or your
safety.
WARNING: Check hose before each use of
barbecue for nicks, cracking, abrasions or cuts. If
the hose is found to be damaged in any way, do not
use the barbecue. Replace using only Weber
authorized replacement manifold assembly. Order
from Weber-Stephen Products Co., Customer
Service Center or authorized dealer.
■ Inspect the burners for correct flame pattern. Clean
if necessary, following the procedures outlined in
the "General Maintenance" section of this manual.
■ Check all gas fittings for leaks.
WARNING: You should check for gas leaks every
time you disconnect and reconnect a gas fitting.
You will need: a soap and water solution and a rag or
brush to apply it.
Make sure main burners are in the OFF position.
Make sure side burner is OFF. Remove valve control
knob and screws. Remove enamel top.
Put the FlameCheck button on the FlameCheck valve.
To perform leak checks: turn on gas supply. Push the
FlameCheck button down and hold down until leak
checking is complete. This will allow gas to fill the hose
and manifold.
WARNING: Do
not ignite burners while leak
checking.
Check for leaks by wetting the connections with the
soap and water solution and watching for bubbles. If
bubbles form or if a bubble grows there is a leak.
Note - Since some leak test solutions, including soap
and water, may be slightly corrosive, all connections
should be rinsed with water after checking for leaks.
Check:
a) Hose to manifold connection. Figure 5 (a).
b) Manifold to side burner hose connection.
Figure 5 (b).
DANGER
Do not use an open flame to check for
gas leaks. Be sure there are no sparks or
open flames in the area while you check for
leaks. This will result in a fire or explosion
which can cause serious bodily injury or
death, and damage to property.
Figure 5
(a)
(b)
(c)
(d)
(e)
Inspection and Cleaning of the Weber Spider Stopper Guards
To inspect the Spider Stopper Guards, remove the
control panel and look to see if they have dust or dirt on
their outside surfaces. If they do, brush off the outside
surface of the Spider Stopper Guards with a soft bristle
brush (an old toothbrush for example). Check that there
are no gaps in the Spider Stopper Guards’ seams or in
the fit around the burners or valves. (See Section
"General Maintenance".)
31
General Maintenance
Weber Spider Stopper Guards
Your Weber Gas Barbecue, as well as any outdoor gas
appliance, is a target for spiders and other insects. They
can nest in the venturi section of the burner tubes. This
blocks the normal gas flow, and can cause the gas to
flow back out of the air shutter. Figure 6. This could
result in a fire in and around the air shutters, under the
control panel, causing serious damage to your
barbecue.
The Weber Spider Stopper Guard is factory installed. It
fits tightly around the air shutter section of the burner
tube and the valve, thereby preventing spiders and other
insects access to the burner tubes through the air
shutter openings. Figure 7.
We recommend that you inspect the Weber Spider
Stopper Guards at least once a year. (See section
“Annual Maintenance”.) Also inspect and clean the
Spider Stopper Guards if any of the following
symptoms should ever occur.
1. The smell of gas in conjunction with the burner
flames appearing yellow and lazy.
2. Barbecue does not reach temperature.
3. Barbecue heats unevenly.
4. One or more of the burners do not ignite.
Figure 6
Figure 7
Venturi
Air shutter
Venturi fin
Weber Spider
Stopper Guard
DANGER
Failure to correct these symptoms
may result in a fire which can cause
serious bodily injury or death and cause
damage to property.
Main Burner Flame Pattern
The Weber Gas Barbecue burners have been factory set
for the correct air and gas mixture. The correct flame
pattern is shown in Figure 8.
If the flames do not appear to be uniform the length of the
burner tube, follow the burner cleaning procedures.
Main Burner Cleaning Procedure
Turn off the gas supply. Remove the manifold.
(See Section “Replacing the main burners”.)
Look inside each burner with a flashlight. Figure 9.
Clean the inside of the burners with a wire
(a straightened out coat hanger will work). Figure 10.
Check and clean the air shutter opening at the ends of
the burners. Check and clean the valve orifices at the
base of the valves. Use a brass bristle brush to clean
outside of burners. This is to make sure all the burner
ports are fully open.
CAUTION: Do not enlarge the burner ports when
cleaning.
Replacing Main Burners
a) Your Weber Gas Barbecue must be OFF and cool.
b) Turn gas OFF at source.
c) Remove control panel: take off the burner control
knobs. Put your fingers under the edge of the
control panel at the control panel push-in buttons
and pull toward you. Lift off the control panel.
Figure 8
Burner inside
cooking box
Flames
Tips occasionally yellowish
Light blue
Dark blue
Figure 9
Figure 10
32
h) Lift and twist the burner assembly slightly, to
separate the crossover tube from the burners.
Figure 14. Remove the burners from the cooking
box.
i) To reinstall burners, reverse steps c) through h).
Crossover tube
Figure 14
d) Unlatch the Spider Stopper Guards and remove.
Figure 11.
e) Use an adjustable wrench to remove the
thermocouple from the FlameCheck valve.
f) Remove the manifold bracket and unscrew the two
thumb screws that hold the manifold to the cooking
box. Pull the manifold and valve assembly out of the
burners and carefully set it down. Figure 12.
g) Slide the burner assembly out from under the guide
screw and washer in the corners of the cooking box.
Figure 13.
Figure 11
View from behind
cooking box
Thumb screws
Figure 12
Guide screw
Figure 13
CAUTION: The burner openings must be
positioned properly over the valve orifices.
Figure 15a.
Check proper assembly before fastening manifold in
place. Figure 15b.
Figure 15
Valve
Burner
(a)
(b)
33
Crossover Ignition System Operations
If the Crossover Ignition System fails to ignite the Front
burner, light the Front burner with a match. If the Front
burner lights with a match, then check the Crossover
Ignition System.
■ Check that both the white and black ignition wires
are attached properly. Figure 17.
■ Check that the Crossover Ignition button pushes the
igniter (button) down, and returns to the up position.
■ Check to see if the igniter is loose in the frame.
Tighten if necessary; see Step “Install igniter” for
correct procedure.
If the Crossover Ignition System still fails to light, contact
Weber-Stephen Customer Service.
Figure 17
White wire
Black wire
j) Reinstall the Spider Stopper Guards. Slightly rotate
the Spider Stopper Guards so that the seams are in
line with the Venturi fins. There should be no gaps
in the seams or in the fit around the burners and
valves. Figure 16.
CAUTION: If the Spider Stopper Guards do not fit
tightly, contact Weber-Stephen Customer Service.
CAUTION: After reinstalling the gas lines, they
should be leak checked with a soap and water
solution before using the barbecue. (See Step
"Check for gas leaks".)
Venturi fin
Check fit around burner
Figure 16
Check fit around
valve
FlameCheck Safety System
The correct positioning of the thermocouple probe is
shown in Figure 18. The tip of the probe is positioned in
the flame. The probe senses the heat from the Front
burner, and activates the FlameCheck valve. The valve
allows the gas to flow into the Front burner. If the Front
burner should go out for any reason, the thermocouple
probe will cool off, thereby closing the FlameCheck valve,
which stops the gas flow to the burners.
If the FlameCheck Safety System should fail to operate,
contact Weber-Stephen Customer Service.
Center line
Thermocouple nuts
Figure 18
1/8 inch
Ignition holes
Wall of cooking box
3535
Problem
Burners burn with a yellow or orange flame, in
conjunction with the smell of gas.
Burner does not light, or flame is low
in HIGH position.
Experiencing flare-ups:
CAUTION: Do not line the bottom tray
with aluminum foil.
Burner flame pattern is erratic. Flame is low
when burner is on HIGH. Flames do not run
the whole length of the burner tube.
Inside of lid appears to be “peeling.”
(Resembles paint peeling.)
Check
Inspect Weber Spider Stopper
Guards for possible obstructions.
(Blockage of holes.)
Is fuel hose bent or kinked?
Does the Front burner light with a
match?
Are you holding the FlameCheck
button down long enough?
Are you preheating barbecue in the
prescribed manner?
Are the cooking grates and
Flavorizer Bars heavily coated with
burned-on grease?
Is the bottom tray "dirty" and not
allowing grease to flow into catch
pan?
Are burners clean?
The lid is porcelain-on-steel, not
paint. It cannot “peel.” What you are
seeing is baked on grease that has
turned to carbon and is flaking off.
THIS IS NOT A DEFECT.
Cure
Clean Weber Spider Stopper
Guards. (See Section "Annual
Maintenance".)
Straighten fuel hose.
If you can light the Front burner
with a match, then check the
Crossover Ignition System.
Hold the FlameCheck button
down for a full eight seconds.
All burners on high for 10 to 15
minutes for preheating.
Clean thoroughly. (See Section
"Periodic Cleaning".)
Clean bottom tray.
Clean burners. (See Section
"General Maintenance".)
Clean thoroughly. (See Section
"Periodic Cleaning".)
TROUBLESHOOTING
If the problem cannot be corrected using these methods, please contact Weber-Stephen Customer Service.
3636
Problem
Side burner does not light.
Flame is low in HIGH position.
Flame is very yellow in conjunction with
the smell of gas,
OR
Burner makes popping noise in conjunction
with the smell of gas.
Push button ignition does not work.
Check
Is gas supply off? Is the Front
burner on?
Is fuel hose bent or kinked?
Inspect the Weber Spider Stopper
Guard for possible obstructions.
(Blockage of holes.)
Does burner light with a match?
Cure
Turn supply on. Light front
burner.
Straighten hose.
Clean Weber Spider Stopper
Guard. (See Section "Annual
Maintenance.")
If match lights burner, check
igniter (see below).
Side Burner Troubleshooting
WARNING: Before attempting any troubleshooting
steps, all gas controls and supply valves should be
in the OFF position.
Side Burner Maintenance
WARNING: All gas controls and supply valves
should be in the OFF position.
Check igniter: Remove side burner cover. To remove
side burner cover, remove control knob and screws that
hold cover to bottom. Figure 19. Make sure wire is
connected between igniter and electrode. Check that
igniter lock nut is tight. Figure 20.
Note - If the igniter works loose, carefully tighten the
igniter lock nut with an adjustable wrench or pliers.
Adjust igniter electrode. Gap should be 1/8 to 3/16 inch
from tip of electrode to burner. Figure 21. Spark should
be a white/blue color, not yellow.
Figure 19
1/8 to 3/16 inch gap
Figure 20
Figure 21
Venturi/Burner
Electrode
Igniter wire
Igniter
3838
®®®®®®®
®
W
E
B
E
R
W
E
B
E
R
1
2
3
7
8
9
10
11
12
13
14
16
21-22
20
23
27
29 30 31 32 33 34
37
17
15
60-63
59
58
52
50
51
49
45-46
48
44
42
41
40
39
38
17
24
35
43
53
4-6
64
25
15
54-56
36
36
26
28
47
57
18-19
21
3939
Parts List
All items are single quantities unless otherwise
specified.
Parts can be ordered directly from Weber-Stephen
Products Co. by phone or mail.
Note - Do not return parts to Weber-Stephen Products
Co. without first contacting the Customer Service
Center by phone or mail. Returning the part may not be
necessary.
While we give much attention to our products,
unfortunately an occasional error may occur.
If a part is missing, do not go back to the store.
Call the Weber Customer Service Center toll free
1-800-446-1071 to receive immediate assistance.
Have your owner’s manual and serial number
of the barbecue available for reference.
Weber-Stephen Products Company
Customer Service Center
250 South Hicks Road
Palatine, IL 60067-6241
(800) 446-1071
1 Lid (assembly)
2 Weber Warm-Up Basket
3 Warming rack
4 Steam-N-Chips Smoker body
5 Steam-N-Chips Smoker flue
6 Steam-N-Chips Smoker water pan
7 Stainless Steel Short Flavorizer Bars (7)
8 Stainless Steel Long Flavorizer Bars (5)
9 Narrow cooking grate
10 Wide cooking grate
11 Serving tray
12 Work table
13 Tubing plugs (4)
14 1/4-20 x 2 inch bolts (5)
15 Swing table end brackets (2)
16 Left frame
17 Swing table assemblies (2)
18 1/4-20 x 1/2 inch bolts (6)
19 Nylon washers (19)
20 Left hand slide bar assembly
21 10-24 x 1 3/4 inch machine screws (4)
22 10-24 hex nuts (4)
23 Caster frame
24 Bottom tray
25 Casters (2)
26 Catch pan holder
27 Catch pan
28 Drip pans (2)
29 Accessory trays (2)
30 Wheel hub caps (2)
31 Wheels (2)
32 Axle
33 Front panel
34 Frame connectors (2)
35 Wheel frame
36 Side burner locks (2)
37 Right hand slide bar assembly
38 Hair pin cotters (2)
39 Hinge pins (2)
40 Thermometer
41 1/4-20 keps nut
42 Cooking box
43 Burner control knobs (3)
44 FlameCheck button
45 Control panel
46 Igniter button
47 Control panel push-in buttons (2)
48 Crossover tube
49 Front or Back burner
50 Center burner
51 1/4-20 stainless steel wing nuts (2)
52 Manifold assembly
53 Manifold bracket
54 Side burner assembly
55 Burner grate
56 Side burner knob
57 Thermocouple
58 Tool holders (3)
59 Right frame
60 Igniter
61 Igniter lock nut
62 Igniter wire (black)
63 Igniter wire (white)
64 Hose
WARNING:
Use only Weber factory authorized parts.
The use of any part that is not factory
authorized can be dangerous. This will also
void your warranty.
A FINAL WORD
OF
THANKS
hank you for choosing a Weber Barbecue.
Our family here at Weber has worked hard
to produce the highest quality products
for your satisfaction.
While we give much attention to our products, an
occasional error may occur. Our knowledgeable
Customer Service staff is prepared to help you with any
problems with parts or assembly.
Call our toll free number 1-800-446-1071.
For quicker service, please have your owner’s manual
available for reference. We also welcome any comments
or suggestions you might have regarding our products.
We wish your family the
best in outdoor cooking enjoyment.
Weber-Stephen Products Company
Customer Service Center
200 East Daniels Road
Palatine, Illinois 60067-6266
T
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